Protective padding layer

ABSTRACT

A flexible padding layer for use during competitive sports is provided. The flexible padding layer is comprised of a plurality of individual padding elements each joined on multiple sides with an adjacent padding element via a thin, connecting section. Each padding element further comprises openings and a three-dimensional surface configuration to allow for consistent mechanical properties throughout the padding layer as a whole.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application derives priority from U.S. Provisional PatentApplication Ser. No. 62/002,230 filed 23 May 2014.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to wearable protective sports padding and,more particularly, to a layer of flexible and lightweight padding that,regardless of orientation, exhibits consistent material properties inall directions while improving impact protection, comfort and fit.

2. Description of the Background

Protecting players from injury is a primary concern for any sport.Sports such as hockey, football and lacrosse feature player-to-playercontact as well as player-to-ground and player-to-equipment (i.e., ball,stick, puck, etc.) contact that has the potential to injureparticipants. Consequently, players participating in such contact sportswear protective gear such as helmets, elbow/knee pads, shin pads,rib/kidney protectors and shoulder pads. To be effective, padding mustabsorb and distribute the force of blows or contact, yet it cannotimpede the player's range of motion, agility and speed. Toward thislatter goal the padding is ideally very light-weight and flexible.Player comfort also requires that pads have adequate ventilation so thatplayers are not overheated or overly fatigued when using their equipmentduring intense physical exertion.

To accomplish these opposing requirements of protection and flexibilitywith minimum restriction, protective gear is typically constructed of anassembly of soft padding in combination with molded, semi-rigid or hardshells or plates. These hard plates configured to be worn by theparticipant over those areas of the body most likely to be impactedduring play of the particular game. The extent and placement of softpads versus hard plates varies depending on where high-impact zonesmight occur, and these zones in turn depend on a variety of factors. Forexample, a lacrosse defenseman performs more stick and body checkingthan he absorbs and so his pads can be lighter-weight. Conversely,lacrosse attackmen require much more robust protection because their jobis to avoid defensemen and score on goal, which makes them the target ofmuch checking and physical contact. In soccer, players wear hard shellprotective gear primarily on their shins, while football players wearhard shell protective gear on their shoulders and heads owing to theareas of hardest contact. A football quarterback's padding howeveremphasizes freedom of motion while a lineman's pads traditionally offermuch more protection.

Hard shell protective gear typically comprises one or more plates ofrigid plastic. While the plates can be manufactured in different sizes,they are not custom fit and are inevitably non-breathable, hard,motion-limiting and less comfortable to wear. It is more desirable thatprotective gear be flexible to allow maximum range of motion but alsoprovide adequate protection to a wide range of players.

Prior art protective gear has made some strides towards pad flexibility,player comfort and range of motion. For example, U.S. Pat. Nos.8,661,564 and 8,627,512 to Dodd describe a protective shin guardcomprised of a plurality of rigid, triangular or round plates joinedtogether by living hinges. The collective plates form a hard “core” thatis disposed inside or on top of an elastomeric or conformable substrate.The plates are free to flex triaxially, each plate pivoting along anaxis relative to an adjacent plate and the axes being one of threeorientations. This gives the collective core some added flexibilitywithout compromising its impact resistance. However, the three-axisflexural design of Dodd is limited by the location and direction of itshinges relative to rigid plates, thereby preventing the hard corepadding from conforming maximally to the player's body and accommodatingits entire range of motion. The Dodd design also is oriented towardlocalized impact absorption rather than widespread impact dispersion,the latter being a benefit of the material described herein.

What is needed then is a more flexible and breathable layer of hardshell padding that is sufficiently conformable to any portion of thebody of a player so as to impose the least possible restriction on theplayer's movement. Further, what is needed is a layer of padding withthese properties to also effectively disperse impact from severe blowsof the type and force anticipated during high-level sports game m whicha ball/puck and stick/bat are necessary implements.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to provide a flexiblepadding layer having material properties and design characteristics tobetter conform to the player's body, impose the least possiblerestriction on the player's movement, withstand blows of significantforce from directions and forces anticipated during particular sportsgames, and increase breathability and comfort of wear.

In accordance with the foregoing objects, the present invention is apadding layer of resilient sheet material defined by a plurality ofuniformly-spaced geometric perforations. Each perforation is surroundedby a marginal surface pattern of varying thickness in the sheet materialto provide relatively equal multiaxial dynamic flexibility in alldirections. In an embodiment, the padding layer comprises a resilientplastic sheet material defined by a plurality of hexagonal perforationsthrough the plastic sheet material. Each hexagonal perforation may besurrounded by a marginal surface pattern of relatively thick triangularfor similarly shaped) sections angularly-spaced around the perforationsand having apices directed toward the perforation. Each triangularsection is joined to both flanking triangular sections by a curvedsection of reduced thickness that facilitates flexion along its verticalaxis. The resulting crown-like structure formed in the sheet materialaround each hexagonal perforation provides comparable flexibility inmultiple directions, as well as substantially uniform tensile strength.Moreover, the hexagonal perforations provide enhanced breathability andreduced weight for the overall padding layer. These advantages aregained without compromising impact-protection, which furtherdistinguishes Applicant's material over the prior art.

For a more complete understanding of the invention, its objects andadvantages refer to the remaining specification and to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features, and advantages of the present invention willbecome more apparent from the following detailed description of thepreferred embodiment and certain modifications thereof, in which:

FIG. 1 illustrates an embodiment of the flexible padding layer accordingto the present invention from above.

FIG. 2 illustrates a side view of the flexible padding layer accordingto the present invention along direction A as indicated in FIG. 1wherein an individual unit of the flexible padding layer is depicted.

FIG. 3 illustrates a side view of the flexible padding layer accordingto the present invention alone direction B as indicated in FIG. 1wherein an individual unit of the flexible padding layer is depicted.

FIG. 4 illustrates a side view of the flexible padding layer accordingto the present invention along direction B as indicated in FIG. 1wherein multiple individual units of the flexible padding layer aredepicted.

FIG. 5 illustrates a perspective view of the flexible padding layeraccording to the present invention from above.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1, an embodiment of a flexible padding layer 1according to the present invention is shown from above. As showntherein, flexible padding layer 1 is generally comprised of a resilientsheet material defined by a plurality of hexagonal perforations throughthe plastic sheet material.

For purposes of description, “resilient sheet material” is hereindefined as any integrally-formed layer or plurality of laminate layersof flexible or semi-flexible material ranging from hard plastics (e.g.,Shore D 100) to flexible or rigid foams (e.g., 10 Asker C), in all caseshaving a shape memory characteristic, and thickness of the crowncomponents of the resilient sheet material (described below) varyinginversely with hardness to provide a desired degree of flexibility.

In the illustrated embodiment, the padding layer 1 is patterned with aplurality of overlapping elements 2, a single one of which is outlinedin bold in FIG. 1. Generally, each element 2 comprises a geometricperforation (triangular, octagonal, hexagonal, etc.) surrounded by a“crown” defined by a marginal surface pattern of varying thickness inthe sheet material. This configuration offers consistent flexibility inmultiple directions.

The dimensions of the flexible padding layer 1 may be varied by anynumber of overlapping elements 2 of uniform size, scaled as desired, andarranged in any number of columns and/or rows without departing from thescope or spirit of the invention.

In an embodiment, the flexible padding layer comprises a resilient sheetof plastic such as polyethylene defined by a plurality ofuniformly-spaced hexagonal perforations 20 through the plastic sheetmaterial. Each hexagonal perforation 20 is surrounded by a marginalsurface pattern or “crown” of relatively thick angular sections 5radially-spaced around the perforations and having apices directedtoward the perforation. The angular sections 5 are preferably triangularand most preferably equilateral triangles. Each hexagonal perforation 20and its surrounding crown of angular sections 5 define one element 2.Any number of elements 2 may be conjoined by overlapping said elements2, sharing some common features of the crown.

When viewed from above, the crown of a single element 2 comprises aplurality of thick, flat triangular sections 5 (six being shown)uniformly spaced around the hexagonal perforation 20 with apicesdirected radially inward. Each triangular section 5 is joined to bothflanking triangular sections 5 by a rounded shoulder 6 of decreasedthickness. Shoulders 6 preferably have a hemispherical cross-sectionrunning along an axis, the axes of which are likewise radially arrayed.The thick triangular sections 5 between shoulders 6 extend from adjacentone hexagonal perforation 20 to adjacent each of its adjoining twoneighbors, facilitating flexion along the vertical axes of shoulder 6.

The resulting crown formed in the sheet material around each hexagonalperforation 20 provides comparable and consistent flexibility inmultiple axes. Moreover, the hexagonal perforations 20 provide enhancedbreathability and reduced weight for the overall padding layer 2. Theseadvantages are gained without compromising impact-protection.

As seen in FIG. 1 each shoulder 6 is radiused lengthwise for improvedtear strength while tapering to a pair of flanking edges 10. Eachelement 2 shares a shoulder 6 with each adjacent element 2. Thus, withineach element 2, each pair of adjacent shoulders 6 diverge along theirrespective axes angularly from a common point proximate the center ofhexagonal perforation 20, and are connected in a triangularconfiguration by a third shoulder 6 belonging to the next adjacentelement 2, the third shoulder 6 straddling the first two and forming thebase of the triangle. The entire plastic area bounded by thesetriangular shoulders 6 constitutes a triangular section 5.

Shoulders 6 extend axially end-to-end between adjoining hexagonalperforations 20 and terminate at opposing edges 11. When perforations 20are hexagonal-shaped, edges 11 form an approximate 45′ angle with theextended plane of edges 10. Where the flexible padding layer 1 is cutlengthwise along shoulders 6, the shoulders 6 will be sectioned leavinga plurality of protruding necks 12, one at each distal end of eachelement 2.

Further as shown in FIG. 1, the hexagonal perforation 20 of each element2 is centered on the center point C and is bordered by an unbrokenhexagonal ring defined by the six endmost-edges 11 ofradially-converging shoulders 6. One skilled in the art will understandthat the overall area of opening 20 may be dictated by design or playerpreference, wherein an opening having a larger surface area may providegreater breathability and lighter overall weight of flexible paddinglayer 1, while a more narrow opening may provide greater protection fromimpacts from small elements that a player may contact during game play.In the preferred embodiment shown in FIG. 1, however, the width of thehexagonal perforation 20 is approximately ⅗ the overall width of element2, while the overall length of the hexagonal perforation 20 isapproximately ⅖ of the overall length of element 2.

The contour profile of the crown of elements 2 when viewed from the sideare shown in FIG. 2-4, where FIG. 2 shows an end view of an element 2 indirection A as indicated in FIG. 1 and where FIG. 3 shows an end view ofan element 2 in direction B as indicated in FIG. 1. With collectivereference to FIGS. 1-3, it can be seen that each element 2 has a maximumthickness T. In addition, those portions of element 2 between the outeredge of element 2 and the outer edge of the hexagonal perforation 20which abut each of the six sides 21, 22 of opening 20 and extendradially therefrom to the mirroring portion of the outer edges 10, 11 ofelement 2 are tapered to a reduced thickness relative to the maximumthickness T of element 2, thereby facilitating flexion along thevertical axes of the radially configured portions. Thus, when viewed,from the side along direction B, as shown in FIG. 3, it can be seen thatapproximately the middle third of edge 10 is depressed relative tomaximum thickness T. Further as seen in FIG. 3, it can be seen that theentire triangular section 5 between shoulders 6 including the sides 22of hexagonal aperture 20 are also depressed relative to maximumthickness T. These areas of reduced thickness decrease towards eachdistal end to a minimum thickness T2, where T2 is within a range of fromapproximately ⅕-½ the maximum thickness T of elements 2, and mostpreferably ⅓. By way of example, in one embodiment T can measure 2.5 mmand T2 can measure 0.7 mm.

Between areas of minimum thickness T2 and areas of maximum thickness T,the surface area of the crown of elements 2 is contoured, formingroughly an hourglass shape when viewed from the side as shown in FIG. 2.Also as can be seen, each face of element 2, upper and lower when viewedfrom the side as in FIGS. 2-3, forms a mirror image with the opposingface

FIG. 5 shows a plurality of elements 2 in perspective view, where thevarying thickness of each element 2 can be seen relative to its lateralshape. Also as shown in FIGS. 1 and 5, a plurality of elements 2 arejoined together along their lateral 10 and distal 13 edges to formflexible padding layer 1. Each element 2 shares two thick triangularsections 5 and one shoulder 6 with each adjoining element 2, and thethick triangular sections 5 between adjoining elements 2 facilitateflexion along the vertical axes of shoulder 6, such that each element 2is permitted a lateral degree of freedom to shift and flex upon impactwith a ball or with another player or other piece of sports equipment.In direction A, as indicated in FIG. 1, flexible padding layer 1 ispermitted to articulate due to the joint operation of the flex regionformed between adjoining elements 2 and the space between adjoiningelements 2 left due to opening 20. Flexibility in direction B, asindicated in FIG. 1, is permitted through the dual operation of the flexregion between lateral edges 10 and the space between adjoining elements2 left due to opening 20. Additionally, flexibility in directions C andD as denoted in FIG. 5 is enhanced through the slimmed profile formeddiagonally along a grouping of elements 2 perpendicular to shoulders 11.

In addition, the spacing, multi-axis orientation, and shape of flexiblepadding layer 1 combine to ensure uniform material properties such asstrength, density, elasticity, etc. in any direction. Unlike prior artpadding, which has similar properties in only a few directions, flexiblepadding layer 1 is isotropic in that all of its physical properties areessentially uniform in all directions. Unlike the prior art, this allowsflexible padding layer 1 to evenly distribute the forces associated withan impact from a ball or other element, while flexibly conforming to theshape and movement of a player's body and resisting tearing or cracking.

The entire flexible padding layer 1 may be formed as a unitary piece byinjection or compression molding. The total number of elements 2included within flexible padding layer 1 may be determined based on theoverall surface area of the desired pad, and/or on the shape and size ofthe portion of a player's body needed to be covered by flexible paddinglayer 1. As can be seen, flexible padding layer 1 is flexible enough toconform to nearly any area of a player's body and to flex with thenatural movement of the player's body. In addition, elements 2 may becut, or partially formed, at edges not corresponding to the naturaledges of same in order to allow flexible padding layer 1 to achieve anydesired lateral shape, such as a trapezoidal shape to cover all or partof a player's chest. In addition, opposite edges of flexible paddinglayer 1 may be joined to form a sleeve or other tubular article capableof being worn around a player's arm or leg, and/or various edges offlexible padding layer 1 may be provided with fastening means and/oropenings, such as for arm or neck holes, to permit flexible paddinglayer 1 to be placed on a player's body.

To adapt flexible padding layer 1 into an article capable of being wornby a player during game play, flexible padding layer 1 may be providedwith fastening means along its outer edges or on one or both of itsfaces to allow it to be securely fastened around a player's body and/orto other padding or garments being worn by the player during the game.In addition, flexible padding layer 1 may be attached at its exterioredges to an elastic fabric material to permit flexible padding layer 1to be incorporated into a larger element of padding or clothing to beworn by a player. Alternatively, flexible padding layer 1 may besandwiched between two layers of elastic, fabric, or other conformablematerial to strengthen a garment being worn by a player.

Having, now fully set forth the preferred embodiments and certainmodifications of the concept underlying the present invention, variousother embodiments as well as certain variations and modifications of theembodiments herein shown and described will obviously occur to thoseskilled in the art upon becoming familiar with said underlying concept.It is to be understood, therefore, that the invention may be practicedotherwise than as specifically set forth in the appended claims.

1. A flexible padding layer, comprising a section of resilient sheetmaterial formed with a repetitive composite pattern of surface features,said repetitive composite pattern comprising a geometric array of aplurality of elements, at least one element of each surface featurebeing shared with an adjoining surface feature, each said surfacefeature further comprising: a geometric perforation; and a contouredcrown surrounding said geometric perforation, said crown including aplurality of shoulders each tapering to opposing edges, said pluralityof shoulders being separated by a plurality angular sections integrallyjoined along said shoulder edges; said surface patterns and perforationscollectively providing consistent flexibility in multiple directions. 2.The flexible padding layer according to claim 1, wherein said pluralityof shoulders each taper to opposing edges having a first thickness, andsaid plurality of angular sections are of greater thickness than saidfirst thickness.
 3. The flexible padding layer according to claim 1,wherein each said shoulder comprises a strut extending from a first endto a second end and along said opposing edges.
 4. The flexible paddinglayer according to claim 3, wherein each said shoulder comprises auniform cross-section between said opposing edges.
 5. The flexiblepadding layer according to claim 4, wherein said uniform cross-sectionis rounded.
 6. The flexible padding layer according to claim 4, whereinsaid uniform cross-section is angled.
 7. The flexible padding layeraccording to claim 3, wherein the first end and second end of each saidshoulders abuts a side of said geometric perforation.
 8. The flexiblepadding layer according to claim 7, wherein said geometric perforationis polygonal.
 9. The flexible padding layer of claim 8, wherein saidpolygonal perforation is octagonal.
 10. The flexible padding layeraccording to claim 9, further comprising six radially-arrayed shoulders.11. The flexible padding layer according to claim 10, wherein saidangular plates are triangular.
 12. The flexible padding laxer accordingto claim 11, further comprising six triangular plates.
 13. The flexiblepadding layer according to claim 2, wherein each said structural elementoverlaps an adjacent structural element.
 14. The flexible padding layeraccording to claim 12, wherein each said structural element overlaps anadjacent structural element by sharing at least on shoulder.
 15. Theflexible padding layer according to claim 1, wherein each saidstructural element overlaps an adjacent structural element by sharingone shoulder and two angular plates.
 16. A flexible padding layer,comprising: a sheet material defined by a composite pattern of surfacefeatures, said composite pattern comprising a repeating array ofstructural elements, each said structural element in said arraycomprising, a polygonal perforation through said sheet material, aplurality of shoulders radially arrayed around said polygonalperforation, and a plurality of angular plates each having a pluralityof sides and each of said sides being integrally attached to one of saidplurality of shoulders, whereby said array of surface featurescollectively provides consistent flexibility in multiple directions. 17.The flexible padding layer according to claim 16, wherein each saidshoulder comprises a strut extending from a first end to a second endand along opposing edges.
 18. The flexible padding layer according toclaim 17, wherein each said shoulder comprises a uniform cross-sectionbetween said opposing edges.
 19. The flexible padding layer according toclaim 18, wherein said uniform cross-section is rounded.
 20. Theflexible padding layer according to claim 18, wherein said uniformcross-section is angled.
 21. The flexible padding layer according toclaim 17, wherein the first end and second end of each said shouldersabuts a side of said polygonal perforation.
 22. The flexible paddinglayer according to claim 16, wherein said polygonal perforation isoctagonal.
 23. The flexible padding layer according to claim 22, furthercomprising six radially-arrayed shoulders.
 24. The flexible paddinglayer according to claim 23, wherein said angular plates are triangular.25. The flexible padding layer according to claim 24, further comprisingsix triangular plates.
 26. The flexible padding layer according to claim16, wherein each said structural element overlaps an adjacent structuralelement.
 27. The flexible padding layer according to claim 26, whereineach said structural element overlaps an adjacent structural element bysharing at least one shoulder.
 28. The flexible padding layer accordingto claim 27, wherein each said structural element overlaps an adjacentstructural element by sharing at least one angular plate.
 29. Theflexible padding layer according to claim 28, wherein each saidstructural element overlaps an adjacent structural element by sharingone shoulder and two angular plates.